Method for producing a ceramic preform

ABSTRACT

For forming a preform of composite material, such as aluminum-based composite material (MMC) by using friction during the forming thereof, ceramic reinforcement, such as Al 2 O 3  and binder are prepared, and the prepared reinforcement and the silanor group binder are put into a die for press forming. During the forming, polycondensation occurs due to frictional heat generated between the fibrous or grain-like particles of the reinforcement and the silanor group binder to harden it, thereby obtaining a preform in which the particles of the reinforcement are fixedly connected to one another.

This application is a divisional of application Ser. No. 09/111,026, filed Jul. 7, 1998,U.S. Pat. No. 6,183,876 which application(s) are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a preform as a basis of a composite material, such as aluminum-based composite material (MMC), and a production method therefor.

2. Description of Related Art

For the purpose of dispersing a reinforcement agent (herein referred to as a reinforcement) throughout a composite material uniformly and so on, in a conventional art, a preform of a predetermined shape is produced, and it is impregnated with melted metal of a matrix-type metal by way of a forging method and an infiltration method, so as to produce a billet.

As a production method for the above-mentioned preform, a wet method is commonly used as shown in FIG. 4. Namely, water, reinforcement (ceramic fiber) and binder are prepared, and after being mixed together and adjusted, the mixture is processed by press-forming. Next, after being removed from the press, the press-formed product is dried so as to form the preform.

The wet method mentioned above, however, has problems in that the number of processes is large, and therefore the time for production is long. Further, the preform is easily broken (has high fragility), for instance, when it is removed from the die, or during the drying and baking processes. Furthermore, since water is required for the wet method, if a process for impregnating the preform with a melted metal is located close to the process for producing the preform, there must be provided means for avoiding contact between the melting metal and the water, and therefore, the wet method comprises obstacles for industrially performing the production processes from the preform to the billet on an in-line process.

Moreover, with the wet method, metal powder, which is added for obtaining a composite material of high strength and high functionality, is oxidized. As a result, it is sometimes impossible to obtain satisfactory results.

Further, according to Japanese Laid-open Patent No. Hei 5-255776 (1993) and Japanese Laid-open Patent No. Hei 6-192765 (1994), etc., there has been proposed a dry method.

In this dry method, ceramic reinforcement and inorganic binder mainly containing SiO₂ are mixed together, and after being formed by applying pressure, the mixture is heated.

Further, a dry method using an organic binder has been disclosed in Japanese Laid-open Patent No. Hei 8-53724 (1996).

In this dry method, in particular in a case where the organic binder is used, the mixture must be heated to a high temperature (600° C. to 1,100° C.) after being formed by the application of pressure thereto. Further, in the conventional dry method using organic binders, it is necessary to add a large amount of binder into the reinforcement. These are all problems.

SUMMARY OF THE INVENTION

An object, in accordance with the present invention, for resolving the drawbacks in the conventional art mentioned above, is to provide a preform and a production method therefor, in which a preform can be obtained by the dry method without using water, which preform has sufficient strength and uses less binder.

Namely, in a preform, in accordance with the present invention, fibrous or grain-line particles in a ceramic reinforcement are bonded to one another into a polycondensation body produced by the polycondensation of a binder of the silanol group, thereby achieving strength higher than 200 kg/cm², being sufficient for the handling thereof.

The ceramic reinforcement mentioned above can be any one containing fibrous, whisker-like, or granular particles therein, and as an example, aggregate alumina can be cited. The aggregate alumina comprises alumina particles of 1-2 μm aggregating to secondary particles of sizes from several tens of μm to several hundreds of μm, and has a very large specific surface. In accordance with the present invention, it is possible to adhere the particles having a large specific surface together (porous body).

Further, the preform can be improved in the characteristic values thereof, by adding thereto metal powder of Fe or Mg or the like.

Moreover, in accordance with the present invention, there is provided a method for producing a preform, comprising the steps of:

mixing a binder of a silanol group with fibrous or granular particle-containing ceramic reinforcement in a ratio which is greater than 0.5 wt % and less than 2.0 wt %;

forming the mixture obtained in the above step and polycondensating the binder of silanol group through friction between the particles of the ceramic reinforcement and the binder of silanol group during the forming; and

bonding the particles of the ceramic reinforcement to one another in a polycondensation body produced by said polycondensation step.

As the silanol group binder, a mixture of silanol and siloxane, or polymethylsilsesquioxane is appropriate. A chemical formula is shown below:

wherein R: —CH₃ or —H

In the case where the mixture of silanol and siloxane is used as the binder, as is shown in FIG. 1, polymethyl siloxane having a molecular weight from 1,000 to 3,000 is produced by the polycondensation between the silanol and the siloxane in a region of low temperature, and thereby the polymethyl siloxane bonds the particles of the reinforcement (Al₂O₃) to one another. Here, the region of low temperature indicates the region of temperature at the time when the preform is formed, and is a temperature approximately in the range of 40° C. to 100° C.

However, if the formed preform is impregnated with melting metal, the polymethyl siloxane is heated to be changed into SiO₂.

FIG. 2 is a graph showing the relationship between the amount of binder added and the strength of the preform when the polymethylsilsesquioxane is used as the silanol group binder. As is apparent from this graph, taking into consideration the handling characteristics, such as setting the preform into a die after the forming thereof, it is necessary that the preform has a strength higher than 200 kg/cm², and it is apparent that the polymethylsilsesquioxane should be greater than 0.5 wt % with respect to the reinforcement for obtaining such a strength.

On the other hand, since the strength of the preform is not additionally improved even if the amount of polymethylsilsesquioxane added is increased above 2.0 wt %, it is therefore preferable that the addition amount of the polymethylsilsesquioxane be greater than 0.5 wt % but less than 2.0 wt %.

There is also as shown the strength when the polymethylsilsesquioxane is changed into SiO₂ in FIG. 2. However, it is not necessary for the preform in accordance with the present invention to be heated so that the polymethylsilsesquioxane is changed into SiO₂.

Further, though having made experiments on binders of the silanol group other than polymethylsilsesquioxane, the same result is obtained in the relationship between the addition amount of the binder and the strength of the preform obtained. Therefore, it is preferable that the amount of binder of silanol group to be added is greater than 0.5 wt % but less than 2.0 wt %.

Here, as the forming method of the preform, for example, press-forming or blow-forming is appropriate.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic diagram showing bonding reinforcement, in the case where silanol and siloxane are used as the binder;

FIG. 2 is a graph showing a relationship between the addition amount of the binder and the strength of the preform, in the case where polymethylsilsesquioxane is used as the binder of silanol group;

FIG. 3 is a process diagram showing a production method of the preform, in accordance with the present invention; and

FIG. 4 is a diagram showing a production method for the preform, in accordance with the prior art.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, detailed explanation of the embodiments according to the present invention will be given by referring to attached drawings.

FIG. 3 is a process diagram showing the production method for the preform in accordance with the present invention, and first of all, in the present invention, ceramic reinforcement of Al₂O₃ or the like and binder are prepared. At this time, for obtaining high strength and high functionality, it is possible to add metal powder, such as Fe, Mg or the like.

Next, the prepared reinforcement and the binder (comprised, in this example, from a silanol group) are mixed and the mix is cast into a die for press-forming. In place of this press forming, blow forming also can be applied.

During the die forming, due to frictional heat generated between the particles of the reinforcement and the silanol group binder, the polycondensation causes the mix to harden, thereby fixedly boding the particles of the reinforcement to one another.

Hereinafter, concrete embodiments and a comparison will be given.

Embodiment 1

To 1,000 g of aggregate alumina (aggregate particle diameter: 40 μm) is added 20 of polymethylsilsesquioxane, and they are mixed by a V-type mixer for 30 min. so as to obtain a powder mixture that is uniformly dispersed. This powder mixture is poured into a press-forming die, and is pressed with a pressure of 200 kgf/cm² to form a preform having, for example, a cylindrical shape, having a diameter of 150 mm and good handling characteristics.

This preform is set in a mold to be impregnated with melted metal of aluminum alloy (5056) by a squeeze cast, thereby obtaining an Al₂O₃/Al composite material. Further, the volume containing ratio (Vf) of the preform in the composite material being obtained is about 25%.

Embodiment 2

To 1,000 g of aggregate alumina (average particle diameter: 40 μm) is added 20 g of polymethylsilsesquioxane, and further 100 g of Fe powder is added thereto. After this, the mix is treated in the same manner as in embodiment 1 to form the preform, thereby obtaining an Al₂O₃/Al composite material. Further, a volume containing ratio (Vf) of the preform in the composite material being obtained is about 25%.

Embodiment 3

To 1,000 g of aggregate alumina (average particle diameter: 40 μm) is added 20 g of polymethylsilsesquioxane, and further 100 g of Fe powder and 20 g of Mg powder are added thereto. After this, the mix is treated in the same manner as in embodiment 1 to form the preform, thereby obtaining an Al₂O₃/Al composite material. Further, a volume containing ratio (Vf) of the reform in the composite material being obtained is about 25%.

Embodiment 4

Forming a preform under the conditions same to those of embodiment 3, the preform and an aluminum alloy (5056) are set in a vacuum furnace. After being purged of nitrogen gas, it is heated to 850° C. under a reduced pressure atmosphere of 200 hPa (hectopascal) to melt the aluminum alloy to be impregnated into the preform, thereby obtaining a composite material. A volume containing ratio (Vf) of the preform in the composite material being obtained is about 25%.

Embodiment 5

To 1,000 g of aggregate alumina (average particle diameter: 40 μm) is added 20 g of polymethylsilsesquioxane, and 20 g of Mg powder is added thereto. After this, the mix is treated in the same manner as in the embodiment 4 to form the preform, thereby obtaining an Al₂O₃/Al composite material. Further, a voluminous containing ratio (Vf) of the reform in the composite material being obtained is about 25%.

Comparison

After adding 1,000 g of aggregate alumina (average particle diameter: 40 μm), 100 g of Fe powder and 20 g of Mg powder into water a solution containing silica sol and stirring them sufficiently, the mix is filtered and pressure-shaped by suction so as to obtain a preform of a cylindrical shape having a diameter of 150 mm. It is further adjusted by a press-forming steps so as to obtain a 25% volume containing ratio (Vf) therein, and this is put into an electric furnace to be heated to 400° C., for the purpose of removing water therefrom and fixing thereof. After cooling, a preform having good handling characteristics can be obtained. With this preform, a composite material is obtained through an activating compound method (a decompression permeation method) which is the same as in embodiment 4.

Measured results of embodiments 1 through 5 and the comparison, i.e., the forming time of the preform, the strength of the composite material and so on, are shown in the Table below. From this table, in accordance with the present invention, the time for forming the preform can be reduced to ¼ that of the conventional comparison, through which it is still possible to obtain sufficient strength. (See Table below.)

TABLE Preform Metal Preform Forming Composite Reinforcement Vf Powder Method Time Method Strength Embodiment 1 Alumina 25 — Dry Method 40 min Squeeze Cast 294 MPa Embodiment 2 Alumina 25 Fe Dry Method 40 min Squeeze Cast 372 MPa Embodiment 3 Alumina 25 Fe, Mg Dry Method 40 min Squeeze Cast 352 MPa Embodiment 4 Alumina 25 Fe, Mg Dry Method 40 min Decompression 352 MPa Permeation Embodiment 5 Alumina 25 Mg Dry Method 40 min Decompression 300 MPa Permeation Comparison Alumina 25 Fe, Mg Wet Method 160 min  Decompression No melting Permeation metal permeates into the preform

As is fully explained above, with the preform and the production method therefor, according to the present invention, since the particles of the reinforcement are bonded by polycondensating the silanol group binder, it is possible to obtain a strength higher than 200 kg/cm² which is necessary for industrial handling of the preform.

In particular, in accordance with the present invention, since the polycondensating of the silanol group binder is carried out using microscopic friction between the ceramic reinforcement particles and the binder when the preform is formed, no specific heating process nor heating apparatus is required.

Further, in general, alumina powder has poor. flowability. Therefore, it cannot easily pass through a hole of a machine for measuring flowability, having a diameter of 5 mm, for example. However, with the addition of the silanol group binder to the reinforcement, it can easily pass through a hole of 5 mm diameter. This means that the melting metal of aluminum can easily permeate into the preform of the present invention. 

What is claimed is:
 1. A dry method for producing a preform comprising the steps of: mixing without using water a silanol group binder with fibrous or granular ceramic reinforcement in a ratio which is greater than 0.5 wt % and less than 2.0 wt % with respect to the reinforcement; forming the mixture obtained in the above step and polycondensating the silanol group binder through friction between particles of the ceramic reinforcement and the silanol group binder during the forming; and bonding the particles of the ceramic reinforcement to one another into a polycondensation body produced by said polycondensation step.
 2. A dry method for producing a preform as defined in claim 1 wherein said silanol group binder comprises silanol and siloxane and said polycondensation body comprises polymethyl siloxane.
 3. A dry method for producing a preform as defined in claim 1 wherein said silanol group binder comprises polymethylsilsesquioxane.
 4. A dry method for producing a preform as defined in claim 1 wherein said forming comprises press-forming.
 5. A dry method for producing a preform as defined in claim 1 wherein the preform is obtained at a temperature of about 40° C. to about 100° C.
 6. A dry method for producing a preform as defined in claim 1 wherein the preform has a strength greater that 200 kg/cm². 